Technical and illustrative data are not binding and can be modified without prior notice. The descriptions and illustrations in the present booklet are for guideline purposes only. THE WHITE BOILER COMPANY a Ravenheat Group Company CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET TEL. 0044 (0)113 252 7007 - FAX: 0044 (0)113 238 0229 Website : www.ravenheat.co.uk - E-mail : [email protected]Instructions for Use Installation and Servicing To be left with the user 86 THE WHITE BOILER COMPANY HIGH EFFICIENCY CONDENSING COMBINATION BOILER WH 100 (T) Natural Gas (G20) I 2H - II 2H3+ G. C. No. 47-506-01 LPG (G30-31) I 2H - II 2H3+ G.C. No. 47-506-02 WH 130 (T) Natural Gas (G20) I 2H - II 2H3+ G. C. No. 47-506-03 LPG (G30-31) I 2H - II 2H3+ G.C. No. 47-506-04
Transcript
Technical and illustrative data are not binding and can be modifi ed without prior notice.The descriptions and illustrations in the present booklet are for guideline purposes only.
THE WHITE BOILER COMPANY a Ravenheat Group Company CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET TEL. 0044 (0)113 252 7007 - FAX: 0044 (0)113 238 0229 Website : www.ravenheat.co.uk - E-mail : [email protected]
Instructions for Use
Installation and Servicing To be left with the user
86
THE WHITE BOILER COMPANY
HIGH EFFICIENCY CONDENSING COMBINATION BOILER
WH 100 (T) Natural Gas (G20) I
2H - II
2H3+ G. C. No. 47-506-01
LPG (G30-31) I2H
- II2H3+
G.C. No. 47-506-02
WH 130 (T) Natural Gas (G20) I
2H - II
2H3+ G. C. No. 47-506-03
LPG (G30-31) I2H
- II2H3+
G.C. No. 47-506-04
2
INSTALLER NOTIFICATION GUIDELINES
A change to Building Regulations (England and Wales) requires the installer to notify
when installing a heating appliance, as from 1st April 2005.
Competent Person's
SELF CERTIFICATION SCHEME BUILDING CONTROL
Install and commission
this appliance to
manufacturers' instructions
Complete the
Benchmark Checklist
Choose
Buildings Regulations
notification route
Contact your relevant
Local Authority
Building Control (LABC) who
will arrange an inspection
or contact a government
approved inspector
LABC will record the data
and will issue a
certificate of compliance
If you notify via
Gas Safe Register they will
then notify the relevant
Local Authority Building
Control (LABC) scheme
on members behalf
Gas Safe Register Engineers
log on to the engineers section
of the website at
www.gassaferegister.co.uk
or telephone
0800 408 5577
You must ensure that the
notification number issued by
Gas Safe Register is written
onto the Benchmark Checklist
Gas Safe Register will record the
data and will send a certificate
of compliance to the property
IT IS A CONDITION OF THE
MANUFACTURERS WARRANTY
THAT THE BENCHMARK
COMMISSIONING CHECKLIST IS
FULLY COMPLETED AND LEFT
WITH THE APPLIANCE
3
HIGH EFFICENCY CONDENSING BOILERFOR CENTRAL HEATING AND DOMESTIC HOT WATER
This new super high effi cient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at super high effi ciency, unheard of only a few years ago.POSITIONThe appliance is extremely versatile as it can be fi tted in almost any room. The appliance is room sealed, there is no contact between combustion chamber and living accommodation. This guarantees maximum safety and effi ciency. Indeed, our front cover has been designed to fi t, achieving maximum air tight seal using screw down fasteners. Each boiler has been designed and manufactured in our modern plant to exacting ISO 9001 discipline, all boilers carry full CE marking of approval. Technical sales and commercial services are available throughout the UK Mainland. This product is guaranteed by The White Boiler Company, Chartists Way, Morley, LEEDS, LS27 9ET. Telephone No (0113) 252 7007.BASIC COMPONENTS - (See fi gure 1).Guarantee is a full 12 months from date of purchase providing the appliance has been fi tted in accordance with these instructions and relevant codes of practice.
- Gas valve.- Variable head pump suitable for any type of central heating system.- Burner with fl ame stabiliser designed to operate under all thermal conditions.- Primary heat exchanger constructed from aluminium.- Unique patented condensing heat exchanger for high thermal fl ue transfer gases to water.- Stainless steel plate heat exchanger for super high heat transfer to domestic hot water supply.- Built in frost protection. - Printed circuit board designed to connect to room stat and/or timer/frost stat. Aesthetically pleasing panels and controls.- On/Off ball valves for shutting off gas, central heating and domestic hot water circuit. Safety relief valve (for safety discharge).Programmable 7 day module with digital display (optional model).All front panel controls not often used have been hidden. This achieves simplicity of operation with easy to clean panels.
NOTE: Due to the high effi ciency of this boiler a plume of water vapour will form at the fl ue terminal during operation.
COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTHIMPORTANT
This appliance contains materials that are indicated below.It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn when handling, where applicable, the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety.
WARNING: when installing the appliance, care should be taken to avoid any possibility of injury when handling sheet metal parts.
GENERAL INFORMATION:GLUES AND SEALANTS - exercise caution - if these are still in liquid form.THE WHITE BOILER COMPANY use only high quality material for production of this product, in an effort to protect the environment components should be re-cycled.
MAJOR COMPONENTS
4
SECTIONS
123456789
101112
INTRODUCTIONDESCRIPTION AND SEQUENCETECHNICAL DATAGENERAL REQUIREMENTSINSTALLATIONCOMMISSIONINGSERVICING INSTRUCTIONSREPLACEMENT OF PARTSFAULT FINDINGELECTRICAL SYSTEM DIAGRAMSPARE PARTS BENCHMARK COMMISSIONINGCHECKLIST DETAILS
23 - Flue temperature sensor 24 - Overheat cut off thermostat 25 - Overheat stat dry fire 26 - Sensing electrode 27 - CH sensor 28 - Fan
GENERAL LAYOUT
Fig. 1
5 5
KEY
1 - Condensate drain2 - Burner3 - Flue gas exhaust manifold4 - Flue temperature sensor5 - Commisioning manual air vent6 - CH fl ow7 - Overheat stat dry fi re8 - Spark electrode9 - Sensing electrode
10 - Fan 11 - Heat exchanger
12 - CH return13 - Gas valve14 - Diferential water pressure switch15 - Water pressure gauge16 - Expansion vessel17 - Auto air vent18 - Circulation pump
19 - Low water pressure switch 20 - Diverter valve motor21 - DHW sensor22 - Plate heat exchanger23 - Safety pressure relief valve24 - Gas service cock25 - Compression ball valves26 - Overheat cut off thermostat
OPERATING SCHEME
Fig. 2
6
etc , with the heating circuit fully charged above 1 bar, so as to operate the low water sensor device the boiler will start in the same way as domestic hot water
mode. As the heating sensor reaches temperature
the fan speed modulates to maintain the temperature set on the display panel. When starting, the fan will always start at the set-point speed.
2.2.8 On the control panel are mounted two potentiometers (thermostats) these control the temperature. One is for domestic hot water and the other for heating.
2.2.9 The boiler is fi tted with an anti-cycling device on the control board. This delays the boiler from re-fi ring within 10 minutes.
If the heating temperature goes 20°C below the set point, the burner restarts immediately. The domestic hot water will always take
priority and is unaffected by the anti-cycling device.
GENERAL FUNCTION
2.3 Central Heating Mode
2.3.1 The potentiometer fi tted on the instrument panel permits regulation of the boiler to partial heating requirements, between maximum and minimum settings.
2.3.2 Air and gas are drawn by the fan for combustion.
2.3.3 The fan also forces exhaust gas through the fl ue to the outside, this creates a lesser pressure in the sealed combustion chamber, thus sucking in combustion air, through the inlet duct.
2.3.4 The boiler water temperature is automatically controlled by a built in thermostat.
2.3.5 Interior space temperature is set by the room thermostat to be installed in the heating system. The boiler already carries connection terminals for this thermostat, as well as for a timeclock.
The burner continues to operate until it is stopped by the timer or one of the thermostats.
2.3.6 When the internal C.H. temperature sensor intervenes the burner shuts down. The fan stops but the pump continues to operate.
2.3.7 When the room thermostats intervene the burner shuts down. The fan stops and the pump after 3 minutes turns off.
2.3.8 The boiler also incorporates an anti-block system which powers the pump every 24 hours, allowing it operate for 2 minutes if the boiler has not been in use. This operation may in some cases be heard for a short period when the pump has been activated.
SECTION 1 INTRODUCTION
1.1 The boiler is designed for the production of central heating and domestic hot water combined in one unit.
It is fi tted with an automatic domestic hot water priority valve.
A summer/winter switch is fi tted on the control panel.
With the Summer only switch position being for domestic hot water.
The summer/winter position being for central heating with domestic hot water priority.
The boiler is equipped with a front cover which can be removed for servicing. The data badge with technical data is placed on the lower part of the left hand side panel.
1.2 Fig.1 Illustrates the general layout of components. Fig.2 Illustrates the operating principles
described in section 2.SECTION 2
2.1 DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION
2.2 Domestic hot water mode
When the appliance is in rest mode with the mains neon switch on. Switch the summer/winter switch to summer position, with the heating circuit charged with water (above 1 bar). If the domestic hot water tap is turned on the boiler will function in the following sequence:
2.2.1 The pump starts. The fan starts and sends a signal back to the ignition board that the fan is running .
2.2.2 The spark ignition system is powered which in
turn commences the spark igniter to operate and light the burner.
At this point the ignition board opens the gas valve to light the burner.
2.2.3 When the electrode sensor senses the signal that the burner is alight, the spark igniter stops.
2.2.4 From the fan speed setting the boiler increases to the maximum permissible speed over a period of 5 seconds and will remain at its maximum required power until its maximum regulated temperature is achieved and then will modulate to maintain this.
2.2.5 When the domestic hot water tap is closed the diverter valve goes back into rest mode, the burner is shut down along with the fan which is also switched off.
2.2.6 Central heating mode
2.2.7 If the switch is positioned on winter with a demand for heat to supply radiators,
7
2.4 Domestic hot water mode
2.4.1 The heat exchanger in the D.H.W. circuit is a stainless steel plate heat exchanger water to water, and domestic water is heated by converting the water in the central heating circuit. The transference of heat is very high because the two fl uids move in a counter direction.
2.4.2 Select summer/winter switch (Fig.33) switch pressed in the winter position.
Switch pressed in, when a hot water tap is turned on the diverter valve motor moves to exclude the central heating circuit, the boiler automatically modulates to maintain the domestic hot water at a constant temperature.
Water temperature can be regulated using the D.H.W. thermostat located on the front control panel (fi g. 33).
2.4.3 When domestic hot water is being drawn the burner and pump perform as they do during central heating except that the burner is commanded by the D.H.W. thermostat.
2.4.4 When D.H.W. is no longer called for the boiler will automatically return to the central heating mode.
2.4.5 Select summer/winter switch (Fig.33) in summer position. The boiler functions like an automatic gas hot water heater. When D.H.W. is no longer required the burner and pump and fan immediately turn off.
This also takes place when the summer /winter switch is on winter if there is no demand forheat to the central heating system or until the timeclock demands for central heating circuit.
2.5 SAFETY DEVICE In both central heating and domestic hot
water mode safe operation is ensured by a control board which shuts off the main burner,
if the fan stops or the fl ue or combustion air intake duct is obstructed.
2.5.1 An overheat cut off thermostat acts to turn off the burner to resetable “lockout”(Fig. 33).
2.5.2 A safety valve is fi tted on the central heating circuit set at 3 bar.2.5.3 A low water pressure switch set at 0.4 bar is
fi tted on heating circuit, to prevent the boiler operating below this boiler system pressure.
GAS RATE max 2.5 m3/hAFTER 10 MINUTES min 0.7 m3/h
INLET PRESSURE 20 mbar
FAN SPEED Max 5400 rpm - 180 Hz Combustion % CO2 : G20 - 9.0 (+ 0.4 / - 0.5) Case ON C.H. min 1650 rpm - 55 Hz G20 - 8.8 (+ 0.4 / - 0.5) Case OFFMixer orifi ce: fucsiaELECTRICAL SUPPLY 230 V ~ 50 HZPOWER CONSUMPTION 160 WEXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265) DRY WEIGHT 39.5 kg WATER CONTENT C.H. 2.0 litre WATER CONTENT 0.5 litreGAS SUPPLY CONNECTION 15 mm compression isolating valveFLOW CONNECTION C.H. 22 mm compression isolating valveRETURN CONNECTION C.H. 22 mm compression isolating valveINLET CONNECTION D.H.W. 15 mm compression isolating valveOUTLET CONNECTION D.H.W. 15 mm compression valveSAFETY DISCHARGE C.H. 15 mm copper pipeCONDENSATION DRAIN 3/4” (21.5 mm) push fi t over fl owMAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 barMINIMUM WORKING PRESSURE 0.5 bar8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 barCENTRAL HEATING OPERATING TEMPERATURE MAX 80°C min 45°CDESIGN FLOW RATE 1383 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/hD.H.W. FLOW RATE 30 °C rise 13.4 l/minD.H.W. FLOW RATE 35 °C rise 11.5 l/minD.H.W. FLOW RATE 40 °C rise 10.1 l/min 10°C inlet temperatureD.H.W. TEMPERATURE Max 60 °C min 40 °CFAN SPEED D.H.W. Max 6300 rpm - 210 Hz min 1650 rpm - 55 HzQmw Input Net Max 29.0 kW min 6.8 kWD.H.W. PRESSURE PMW Max 10 bar (147 p.s.i.) D.H.W. PRESSURE PMW min 0.8 bar (118 p.s.i.) To obtain heat input 1.2 barD.H.W. MINIMUM FLOW RATE 3 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required)DESTINATION: AT, DK, Fl, SE & GR CATEGORY I2H
GAS RATE max 3.4 m3/hAFTER 10 MINUTES min 0.85 m3/h
INLET PRESSURE 20 mbar
FAN SPEED Max 5400 rpm - 180 Hz Combustion % CO2 : G20 - 9.0 (+ 0.4 / - 0.5) Case ON C.H. min 1650 rpm - 55 Hz G20 - 8.8 (+ 0.4 / - 0.5) Case OFFMixer orifi ce: redELECTRICAL SUPPLY 230 V ~ 50 HZPOWER CONSUMPTION 160 WEXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265) DRY WEIGHT 42.5 kg WATER CONTENT C.H. 2.0 litre WATER CONTENT 0.5 litreGAS SUPPLY CONNECTION 15 mm compression isolating valveFLOW CONNECTION C.H. 22 mm compression isolating valveRETURN CONNECTION C.H. 22 mm compression isolating valveINLET CONNECTION D.H.W. 15 mm compression isolating valveOUTLET CONNECTION D.H.W. 15 mm compression valveSAFETY DISCHARGE C.H. 15 mm copper pipeCONDENSATION DRAIN 3/4” (21.5 mm) push fi t over fl owMAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 barMINIMUM WORKING PRESSURE 0.5 bar8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 barCENTRAL HEATING OPERATING TEMPERATURE MAX 80°C min 45°CDESIGN FLOW RATE 1811 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/hD.H.W. FLOW RATE 30 °C rise 17.0 l/minD.H.W. FLOW RATE 35 °C rise 14.5 l/minD.H.W. FLOW RATE 40 °C rise 12.7 l/min 10°C inlet temperatureD.H.W. TEMPERATURE Max 60 °C min 40 °CFAN SPEED D.H.W. Max 6300 rpm - 210 Hz min 1650 rpm - 55 HzQmw Input Net Max 36.4 kW min 7.8 kWD.H.W. PRESSURE PMW Max 10 bar (147 p.s.i.) D.H.W. PRESSURE PMW min 0.8 bar (118 p.s.i.) To obtain heat input 1.2 barD.H.W. MINIMUM FLOW RATE 3 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required)DESTINATION: AT, DK, Fl, SE & GR CATEGORY I2H
I.S. 813 Domestic gas Installations. The followings standards give valauable additional information:
BS 5546 Installation of hot water supplies for domestic purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings. Circulation of load. BS EN 14336 Installation & commissioning of water based heating systems. BS 7074 Expansion vessels and ancillary equipement for sealed water system. BS 7593 Treatment of water in domestic hot water and central heating system.
Health & Safety Document No.635 The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.
IMPORTANT: These appliances are CE certificated for
safety and performance. It is, therefore, important that no external control devices e.g. flue dampers, economisers etc., are directly connected to this appliance unless covered by these Installation and Service Instructions or as otherwise recommended by Ravenheat in writing. If in doubt please enquire.
Any direct connection of a control device not approved by The White Boiler Company could invalidate the certification and the normal appliance warranty.
It could also infringe the Gas Safety regulations and the above regulations.
NOTE: The White Boiler Company WH 100/130 combi
boiler has been tested and examined by BSI, and is certified to comply with PrEN 483 and BS EN 625.
Manufacturers instructions must NOT be taken in any way as overriding statutory obligations.
If in doubt on any point please consult The White Boiler Company.
4.2 LOCATION OF BOILER
4.2.1 Siting of The White Boiler Company WH100/130 combi boiler must be as follows.
The position of installation should be within the building, unless otherwise protected by a suitable enclosure.
SECTION 4 GENERAL REQUIREMENTS
4.1 SAFETY Gas Safety (Installation and Use).
Regulations. It is law that all gas appliances are installed
and serviced by a Gas Safe registered installer in accordance with the above regulations and these installation instructions. All registered installers carry a Gas Safe I.D. card and have a registration number. Both should be recorded in your Benchmark commissioning checklist. You can check your installer on the Gas Safe register. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with. Check the boiler and flue is the correct type for installation.
The installation of the boiler MUST be in accordance with the latest I.E.E. (BS 7671) Wiring Regulations, local building regulations, bye-laws of the local water authority, the building regulations and the Building Standards (Scotland) and any relevant requirements of the local authority.
4.1.1 GENERAL INFORMATION Both the user and the manufacturer rely
heavily on the installer, whose job it is to install the combination boiler and connect it to a correctly designed heating system. Acquaint yourself with the relevantBritish Standards concerning installation requirements. If you need further advice on any points contact the Technical Services Office who would be pleased to help. It is recommended that tools suitable for brass fittings are used, and have a capability to accomodate hexagon sizes up to 50 mm.
CODES OF PRACTICE/Ref: Documents. Detailed recommendations are contained in the
following British Standard Codes of Practice:
BS6891: Low pressure installation pipes.BS6798: Installation of gas fired hot water boilers of rated input not exceeding 70 kW.BSEN12828BSEN12831BSEN14336BS5546: Installation of gas hot water supplies domestic purposes (2ndFamily Gases). BS5440: 1 Flues (for gas appliances of rated input not exceeding 70 kW).
BS5440: 2 Ventilation (for gas appliances of rated input not exceeding 70 kW).
BSEN 677:1998 Gas fired central heating boilers.
12
Directive 89/336/EEC and are therefore permitted to carry the CE Mark.
The appliance has been tested and approved by the WRc as meeting the requirements of G3 and L of the Building regulations and water Bylaws Scheme - Approved Products.
4.5 GAS SUPPLY
4.5.1 A gas meter is connected to the service pipe by the Local Gas Region or the Local Gas Region contractor. An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves. Installation pipes should be fitted in accordance with BS 6891. Pipework from the meter to the boiler must be of adequate size (22 mm) min to within at least one metre of the boiler, (15 mm) min. can then be used for remaining pipe work to the appliance. A smaller size than the boiler inlet gas connection should not be used. The complete installation must be tested for soundness as described in the above Code.
N.B. if the gas supply for the boiler serves other appliances ensure an adequate supply is available both to the boiler and the
other appliances when they are in use at the same time.
4.6 FLUE SYSTEM
4.6.1 The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discolouration that might occur to building products in the vicinity (see fig. 5).
The terminal must not be located in a place where it is likely to cause a nuisance In cold and/or humid weather as water vapour may condense on leaving the flue terminal.
The effect of such pluming must be considered.
The terminal must not be closer than 25 mm (1 in) to any combustible material For protection
of combustibles, refer to BS 5440.1. Where a flue terminal is installed less than
1000 mm. from a plastic, or painted gutter; or 500 mm from painted eaves, an aluminium shield 1000 mm. long, should be fitted to the underside of the gutter or painted surface.
Pluming will occur at the terminal so, where
possible, terminal positions which could cause a nuisance should be avoided.
The flue must be installed in accordance with the recommendations of BS 5440: Part 1.
IMPORTANT NOTESFor greater fl ue lengths see alternative fl ue instructions. Flue must be positioned in a place not likely to cause a nuisance from pluming.
Adequate space for installation, servicing and air circulation around boiler must be allowed for.
The The White Boiler Company WH 100/130 combi boiler must be fitted on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment.
The appliance may be installed on a combustible wall subject to the requirements of the Local Authority and Building Regulations.
LPG versions of this appliance shall not be installed in cellars or basements.
4.3 CLEARANCES AROUND THE APPLIANCE (Fig. 14a)
4.3.1 Side clearance: The position of the appliance must be provide the following minimum clearance which is necessary for removal 55 mm. Top clearance: The top clearance should be a minimum of 125 mm. Bottom clearance: A bottom clearance of 80 mm is required between the appliance and any surface. Though 150 mm is preferred whenever possible. Front clearance: A minimum of 450 mm is required in front of the appliance for access during servicing, the front clearance can be reduced when installed in a cupboard, to 25 mm from the access door. 4.4 IMPORTANT NOTICE
4.4.1 For installation into timber framed buildings, please refer to the Institute of Gas Engineers Document IGE/UP/7.
The combination boiler may be installed in any room or internal space, although particular
attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and in Scotland the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space containing a bath or shower. Where a room sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control, utilising mains electricity should be so situated that it cannot be touched by a person using a bath or shower.
A compartment used to enclose the combination boiler MUST be designed and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified accordingly Samples of the WH 100/130 combi boiler have been examined by B.G. Technology Notified Body, and is certified to comply with the essential requirements of the Gas Appliance.
Directive 90/396/EEC, the Low Voltage. Directive 72/23/EEC and shows compliance with
the Electro Magnetic Compatibility.
13
14
Fig.5
FLU
E T
ER
MIN
AL
PO
SIT
ION
15
IMPORTANT NOTICE: If the fl ue terminates below a balcony, above the ground, above a fl at roof to which people have access, then a suitable terminal guard must be fi tted PRO110100. Fit only recommended FLUE TERMINAL GUARD by securing concentrically around terminal with screws. Available on request from:
The White Boiler Company Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - UK Tel.0044(0)113 252 7007
IMPORTANT: The following notes are intended for general guidance.The boiler MUST be installed so that the terminal is exposed to external air.
It is important that the position of the terminal allows the free passage of air across it at all tirnes.
Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specifi ed in Fig. 5.Note positions: Due to the terminal design, installation is possible with clearances less than those specifi ed in BS 5440, Part 1
NOTE: The flue must be terminated in a place not likely to cause a nuisance.
4.6.2 A concentric vertical flue kit is available for flueing applications up to a maximum height
(see table 3 page 19). For further details see vertical flue installation
instructions.
4.7 AIR SUPPLY
4.7.1 The following notes are intended for general guidance.
The room sealed fan flued boiler does not require a permanent air vent for combustion air supply.
Where installed in a cupboard or compartment ventilation is not required.
4.8 WATER CIRCULATION (central heating)
4.8.1 Detailed recommendations are given in BS6798 2009/5449:1990 - BSEN12828 - BSEN12831 - BSEN14336 (for smallbore and microbore central heating systems). The following notes are given for general guidance.
4.8.2 PIPEWORK. Copper tubing to BSEN 1057:1 2006,
BSEN 1172, BSEN 1652 and BSEN 1653, is recommended for water pipes. Jointing should be either with capillary soldered or with compression fittings.
Where possible pipes should have a gradient
to ensure air is carried naturally to air release points and water flows naturally to drain taps. It should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air except where providing useful heat, pipes should be insulated to prevent heat loss and to avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.
IMPORTANT. A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping.
4.8.3 The water through the appliance heat exchanger circuit must exceed the min. 2.38 gals/min. (650 It/h) when the burner is firing. It is important to ensure that this rate is achieved when sections of the system are shut off either manually or by automatic controls.
If the volume of circulating water is too low, the boiler water temperature will rise too rapidly. This could cause noise in the system or even cause the safety thermostat to trip.
4.8.4 BOILER INTERLOCK CONTROL Central heating systems controls should be installed to ensure the boiler is switched off
when there is no demand for heating, in compliance with Building Regulations.
The boiler has its own built in bypass. If the system has thermostatic radiator valves
on all radiators, or two port valves, then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position.(See fig. 6).
4.8.5 It is important that the system is flushed thoroughly before the appliance is fitted or left to operate (as recommended in BS 7593) in order to maintain an efficiently operating heating system. For replacement installations, the system MUST be flushed with the old boiler in situ. In order to prevent system debris. Once the system has been flushed, an inhibitor
(suitable for stainless steel heat exchanger) should be added. See section 4.8.11.
Fig.6
16
4.8.6 Draining tap These must be located in accessible positions
to permit the draining of the whole system. The taps must be at least 15 mm nominal size and manufactured in accordance with BS 2870 1980.
4.8.7 Air release points These must be fitted at all high points where
air will naturally collect, and must be sited to facilitate complete filling of the system.
4.8.8 The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated.
It can accept up to 8 Its of expansion water. If the appliance is connected to a system with an unusually high water content, calculate the total expansion (see table 2) and add additional sealed expansion capacity as appropriate (Fig. 7). In general, modern systems below 8 litre should not present any problem.
4.8.9 Mains water feed: central heating There must be no direct connection to the
mains water supply, even through a non return valve, without the approval of the Local Water Authority.
Figure depicts the requirements of Diagram R24.2a of the Water Supply (Water Fittings) regulations 1999.
Fig.7
4.8.10 Permissible methods of filling
Fig.8
17
B) Where fitting of a make up vessel would be difficult, re pressurisation of the system can be done. See section on FILLING. If the capacity of the central heating system should exceed 110 Litres, an additional vessel should be installed on the return to the combination boiler from the heating system (Fig. 7). Guidance on vessel sizing is given in (Table 2).
Reference should be made to British Gas Publications, «Material and Installation Specifications for Domestic Central Heating and Hot Water». Draining taps should be at least 1/2” in BSP nominal size and be in accordance with BS 2879.
4.8.11 Installation to an existing central heating system
The combination boiler is designed to operate on a sealed system only. Therefore if the existing system is of the open water type it will have to be modified to comply with BS 5376 Part 2.
Before installing a new combination boiler to an existing system, flush out the old system with a recommended descaling agent.
If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleaning.
BS 7593:2006 details the steps necessary to clean domestic central heating system. Also check pipework and renew any corroded pipework or fittings. Valve glands must be repacked or replaced wherever necessary and any defective controls exchanged.
WATER TREATMENT This boiler has a aluminium and stainless
steel heat exchanger, The White Boiler Company recommended the use of FERNOX or SENTINEL, or other treatment products recognised by The White Boiler Company which must be used in accordance with the manufacturers instructions.
SIZING OF ADDITIONAL EXPANSION VESSEL: TABLE 2Deduct from the value given in the table the 7 litre vessel supplied.
Note: This pressure can be increased up to 1.5 bar to suit high static head situations.
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4.8.12 Hard water areas If the area of installation is recognized as hard
water, it is recommended that a suitable water treatment device is installed in the mains.
The water hardness can be determined by using the standard test paper or by referring to local water authority.
4.9 DOMESTIC WATER
4.9.1 The domestic hot water must be in accordance with the relevant recommendations of BS 5546. Copper tubing to BS 2871 1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water.
4.10 ELECTRICAL SUPPLY
Warning: this appliance must be earthed
4.10.1 External wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E. Regulations and local regulations which apply. The White Boiler Company boiler is supplied for connection to a 230 V ~ 50 Hz single phase supply. The supply must be fused at 3 A.
NOTE. The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance, by the use of a fused, double pole isolator, having a contact separation of at least 3 mm in all poles. The point of connection to the electricity supply must be readly accessible and adjacent to the appliance except, where the appliance is installed in a bathroom.
When the current electrical wiring regulations must be followed in GB the IEE Wiring Regulations and in IE the ETGI Rules.
SECTION 5 INSTALLATION
5.1 WARNING
5.1.1 It is MOST IMPORTANT that this appliance is installed in a VERTICAL POSITION, with the flue air duct passing through the wall.
Make sure the flue is at a 1.5° incline, rising from the boiler with 50 mm.
Flue terminal diagram states 1.5° - 25 mm, fall back on flue (see fig. 5).
5.2 DELIVERY
5.2.1 The appliance carton contains a) boiler fully assembled with fl ue adaptor b) installation instructions, user instructions and Benchmark log book c) white paper template d) hanging bracket e) guarantee card f ) Polythene bag containing: -1-15 mm gas service - 2-22 mm compression ball valves complete with 3/4” washers - 1-15 mm compression ball valves complete with 1/2” washers - 1- 15 mm compression ball valve - 2 fi xing bolts and wall plugs - screws and dowels.
IMPORTANT NOTES : This appliance will produce a plume of condensation in cool weather. This is due to the High Effi ciency and hence low fl ue gas temperature of the boiler. See Optional extras (Fig.12).
5.3 UNPACKING OF BOILER
5.3.1 IMPORTANT: With regard to the Manual Handling Operations, 1992 Regulations,
the following lift operation exceeds the recommended weight for a one man lift.
5.3.2 - Stand the boiler carton upright. - Open the top of the carton. - Rest the carton on the fl oor (keeping the fl aps open). - Turn the carton over with the boiler inside and then pull the carton up away from the boiler. - Rest the boiler on its back on the fl oor to prepare it for installation.
5.4 POSITIONING OF THE BOILER
5.4.1 Remove the 2 lower and the 2 upper screws that secure the front panel, and then lift off.
5.4.2 Unscrew the 4 screws that fasten the lower grating on the casing and remove it from the bottom of the casing.
5.4.3 Make sure the casing and screws are put to one side in a safe place.
Fig.9
IMPORTANT: Please, lubricate the internal part of the seals before being fitted.
19
TYPE OF FLUE SYSTEM (All types) - minimum and maximum distance TABLE 3
59 - Rubber seal Ø 60 56 - Rubber seal Ø 100 60 - Fumes sample point 61 - Flue exhaust duct 62 - Air intake duct 69 - Air sample point 127 - Terminal Rubber wall seal 128 - Elbow header
Fig 11
Fig 10
WARNING: with horizontal concentric fl ueMaximum allowable fl ue length 8 m maximum, fl ue duct extension used with standard fl ue (see table 3).
FLUE EXTENSION BOX CONTAINING (Fig. 11): 1000 mm fl ue extension duct as an extra cost only when requested for side and vertical fl ue applications.
59 - Rubber seal Ø 6063 - Air intake duct extension
64 - Flue exhaust duct extension
Generally speaking,oils and greases are not suitable for the “peroxide -EPDM”, therefore we suggest a correct lubrication using silicon-substances, for instance “Silikon Spray“ (Arexons)or the same product from the company “Soltecno s.r.l.”.
Plume Management Kit
Maximum Length (mm) 6000 minimum length (mm) 500
Equivalent length of 45° bend (mm) 500 Equivalent length of 90° bend (mm) 1000
IMPORTANT : Max fl ue length must not exceed 6 m with a horizontal concentric 60/100 fl ue of 3m ( L )
Fig. 12
The Maximum permitted fl ue length is measured from the centre line of the fl ue terminal to the top of the outlet terminal
PLUME MANAGEMENT KIT (Fig 12) Max 6000 mm fl ue extension duct as an extra cost only when requested to reduce pluming nuisance of condensation from 60/100 horizontal concentric fl ue.
IMPORTANT :Please, lubricate the internal part of the seals before being fitted.
Fig. 12a
FLUE EXHAUST DEFLECTION BEND (Fig 12a) Flue exhaust defl ection bend are also available. These come in both 45° and 90° degree versions. These bends fi t directly onto the fl ue exhaust terminal to defl ect the fl ue gas plume in an upward or sideways direction.Although they are not substitute for a plume kit, they can be considered useful where condensate pluming is causing a nuisance or can be used to eliminate condensate collecting on the end of the horizontal fl ue terminal.
20
OPTIONAL EXTRAS:
Plume Management Kit Part No.
Part. No. Description TER110101 1 metre high plume kit containing: (Fig. 12) n. 1 terminal bend n. 1 90° elbow bend n. 2 45° bend n. 1 metre 60 M-F fl ue length n. 1 fl ue length bracket
CUR110050 45° fl ue exhaust defl ection bend (Fig. 12a)
CUR110100 90° fl ue exhaust defl ection bend (Fig. 12a)
L+L max 6000 mmminimum plume kit length 500 mm
21
5.5 INSTALLING THE APPLIANCE FOR REAR FLUE OUTLET (Fig. 13 15 16 17 18 19). FOR APPLIANCE CLEARANCES SEE 4.3.1 AND FIG. 5.
5.5.1 Use adhesive tape to attach the template to the wall, making sure that the centre line is vertical and that the distance clearance is no less than that shown in Fig. 13. - Mark the two holes to fix the hanging bracket on the wall as well as the centre of the flue duct.
- Detach the template from the wall.- Use a 10 mm. dia drill to make the 2 holes.
Insert the plastic expansion plugs.- Cut or core drill a 105 mm dia hole for inserting the flue duct.- Locate the wall hanging bracket and fix using the two coach bolts.Fit the elbow header positioning it towards the required direction (Fig 13), onto the boiler.
Fig 135.5.2 Make sure that the rubber Ø 60 is locate into the flue elbow header.
5.5.3 If using horizontal flue duct and it is too long it can be shortened. Should it be necessary to cut the flue always. Cut equal amounts from both inner and outer pipes. Note : add 30 mm to overall flue length to allow for terminal wall cover.( Fig.10 item 127).
5.5.4 Insert the flue assembly into the wall.
5.5.5 Lift the boiler on to the wall (Fig.13), locating onto the fixing jig wall bracket.
5.5.6 Working above the boiler pull the flue exhaust duct towards the boiler in order to engage tube (Fig. 17 item 61) into its header.
Position flue into elbow header and push so as to locate inner and outer flue correctly ensuring good seal is made with “O” rings.
5.5.7 Fit terminal rubber wall seal and if necessary terminal guard.
5.5.8 Extensions kits are available to order for flue extension of up to 7 metres total length (Fig.18).
5.5.9 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of seven extensions.
Pipeline length can be established using the instructions in section 5.5 for rear flue outlets and section 5.6 for side flue outlets. Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal.
NOTE: Recomended clearance each side of boiler 55 mm.
5.6 INSTALLING THE APPLIANCE FOR SIDE FLUE OUTLET (Fig. 14 15 16 17 18 19)
5.6.1 - Attach the template to the wall with adhesive tape, making sure that the centre line is
vertical and that the distance from the centre line to the nearest side wall is not less than measurement in Fig.14.
- Mark the two fixing bracket securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it is horizontal.
- Make sure flue slopes 1.5° down towards the boiler that is 25 mm fall per metre
of the flue length.- Trace the centre of the flue duct hole measure
distance . From the corner of the wall (Fig.14), measure the distance (160 mm) between the centre of flue duct hole to the corner.
Detach the template from wall.- Use a 10 mm. dia. drill to make the 2 holes for
securing hanging bracket fixing. Insert the plastic expansion plugs. Core drill a 105 mm dia. hole in the side wall for inserting the flue duct.
5.6.2 Positioning the elbow towards the required direction on the boiler.
5.6.3 Make sure that rubber seal Ø 60 is locate into the elbow.
REAR FLUE OUTLET
22
Fig. 14
5.6.4 If using horizontal flue duct and it is too long it can be shortened. Should it be necessary to cut the flue always.Cut equal amounts from both inner and outer pipes. Note : add 30 mm to overall flue length to
allow for terminal rubber wall seal.( Fig.10 item 127).
- Remove the centering spring, pull the flue terminal disengage inner flue duct. - Measure the thickness of the wall.- Cut the outer air duct (100 mm. dia.) at right angles. - Cut the inner flue duct (60 mm dia.) at right angles.- Outer air duct and inner flue duct must be de-burred.
- Reassemble the two tubes.
5.6.5 Insert the flue assembly into the wall, making sure it will not interfere when fixing the boiler on the wall.
5.6.6 Lift the boiler on the wall. Locate onto the wall fixing bracket.
5.6.7 Working above the boiler pull the flue duct towards the elbow in order to engage the tube into its header (Fig.10). Position flue into straight header and push so as to locate inner and outer flue correctly. Ensuring good seal is made with “O” rings.
5.6.8 IMPORTANT: Terminal rubber wall seal must be fitted (Fig.10 item 127).
5.6.9 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of seven extensions.
Pipeline length can be established using the instructions in section 5.5 for rear flue outlets and section 5.6 for side flue outlets. Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal.
Extensions must be joined together with the standard terminal pipe, and inserted in each other as far as they can go.
If an extension must be shortened, this must be done from the straight end, and not from the widened or tapered end. To measure the pipeline properly all components must be assembled and total length measured before cutting. The straight end of the extension connects to the boiler. The flue output and air intake pipes fits into the boiler header until it stops (Fig.17 - Fig.18).
When cutting both inner and outer ducts of the extension, always ensure that the reduced end (male) of the inner and outer duct are square and to the same length.
All joints must be sealed with the rubber seals supplied.
It is important to put the centering spacer, supplied with the unit, inside between the two pipes, from the side opposite the extension’s straight end.
NOTE: a suitable support bracket is available from The White Boiler Company and should be used to support flue length at least every one metre preferably at each joint this bracket should be secured to wall and flue duct.
NOTE: Recomended clearance each side of boiler 55 mm.
SIDE FLUE OUTLET
Fig. 14a
INTAKE AND EXHAUST TERMINAL COMPONENTS
Fig.17
IMPORTANT: Please, lubricate the internal part of the seals before being fitted.
IN LINE FLUE BEND AND FLUE EXTENSION
Fig.19
128 - In line Flue Bend 59 - Rubber seal Ø 60 63 - Air intake duct extension 64 - Flue exhaust duct extension
23
KEY
56 - Flue adapter57 - Elbow header58 - Header gasket59 - Rubber seal Ø 6060 - Fumes sample point
66 - Securing screw67 - Flue temperature sensor69 - Air sample point127 - Terminal Rubber wall seal
Fig 15
Fig.16
5.7.2 IN LINE FLUE BEND Measure the distance between the flue bends or
the flue/terminal assembly. The measurements should be taken from the outer edge of the flue and bend (Fig. 19).
IMPORTANT: inline flue bend - 1000 mm must be deducted from overall length for each 90°bend. Obtuse flue bend - 500 mm must be deducted from overall length for each 135° bend (Table 3 page 19).
5.7 COMPLETING BOILER INSTALLATION
5.7.1 Reassemble the outer casing (sect 5.4) in reverse order.
Fig.18
L + L = 8m Max
Fig. 20
Straight Flue Straight Flue Offset Flue Offset Flue L = 12.0 m Max L = 12.0 m Max L = 10 m Max L = 11 m Max plus Terminal plus Terminal plus 2 bend 90° plus 2 bend 45° and Terminal and Terminal
Fig. 21
24
5.7.3 VERTICAL FLUE INSTRUCTION ONLY (Fig. 20-21-22) SEE FIG. 5 FOR PERMISSIBLE FLUE POSITION
IN LINE FLUE BEND - 1000 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90° BEND OBTUSE FLUE BEND -500 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135° BEND.
The vertical flue kit is intended for use wherea horizontal flue outlet is not possible or desired.The vertical flue can be used either with a flat roof or a pitched roof (maximum pitch 60°).Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and inline 135°/90° flue bend (Fig. 20).
Proceed with installation as detailed in section 5 up to 5.5.8., of the main Installation and Servicing Instruction, ignoring all references to horizontal flue installations.Use adhesive tape to attach the template to the wall, making sure that the centre line is vertical and that the flue centre line is virtually below the point at which the flue will exit the roof.
- Ensure that the maximum permissable flue length is not exceeded (Fig. 21 and table 3).- Mark the two wall fixing bracket securing holes on the wall.- Detach the template from the wall.- Use a 10 mm dia. drill to make the 2 holes securing fixing hanging bracket. Insert plastic expansion plugs (Fig. 18).- Screw in the two coach bolts.
- Position the flue sample point starter (must be fitted) and fix the securing screw on the flue adaptor appliance (Fig. 23) item 66, and ensure that the gasket is correctly fitted.
Important: Make sure that the flue extension dia 60 mm duct is inserted fully into the flue manifold, and the flue manifold rubber seal is correctly fitted.
IMPORTANT NOTES : For greater flue length see twin flue or concentric 80/125 flue instructions
IMPORTANT: Please, lubricate the internal part of the seals before being fitted.
Straight Flue Offset Flue Offset FlueL = 12.0 m Max L = 12 m Max L = 11 m Max plus Combi ridge plus 2 bend 90° plus 2 bend 45° and Combi ridge and Combi ridge
25
Fig. 22
Starting at the appliance end, assemble the extension duct sections, making each inner and outer (flue) joint by inserting the spigot end into the socket end of the next tube, making sure the seal rings are correctly located (Fig. 23). Make sure that the entire flue is adequately supported. Use at least one bracket for each extension used.Ensure that all inner flue connections have a good fit/seal, and that the space clips in each extension are correctly positioned.
Fig.23
Fig.24
Cut a 105 mm diameter hole through the ceiling and/or roof, at the point previously marked.Fit a roof flashing slate to the roof, available from The White Boiler Company.Insert the Vertical Flue terminal assembly through the flashing slate from the outside.Fix the appliance to the wall, locating onto the wall fixing bracket.Measure the vertical distance between the top of the flue and the bottom of the flue terminal assembly (Fig. 22). The measurements should be taken from the outer diameter of the flue.NOTE: Where this length does not match any standard combination of the extensions, only extension can be cut to the required length (Fig. 24).When cutting both inner and outer ducts of the extension, always cut on spigot side, and they must be de-burred.
IMPORTANT: Please, lubricate the internal part of the seals before being fitted.
26
IMPORTANT These instructions must be read in conjunction with the main installation and servicing instructions. As with all fl ues the kits must be installed taking due account of the current issue of BS 5440 parts 1 & 2 and timber frame housing DM2 is referenced to the Institute of Gas Engineers Document IGE/UP/7. Also note that the requirements will vary depending upon the kit being installed. Guidance is provided but unless otherwise stated, always comply with the recommendations of the relevant codes of practice.
Make sure that the Flue manifold rubber seal is locate into the fl ue manifold, and lubricate the internal part of the seal before assembly.Locate the header gasket on the twin fl ue header and push into the fl ue adaptor (Fig.17 item 56) making sure that the inner plastic exhaust locates fi rmly in the outlet spigot of the fl ue manifold, and screw the securing screw that secure the twin fl ue header on the boiler.
Locate the 2 x 80 mm ‘O’ rings in the twin flue header and lubricate the internal part of the seal before assembly to ensure easy snug fi t.
Figures show the versatility of this flueing system. Measurements and bends must be calculated correctly so as not to oversize maximum flue lengths.All located ‘O’ rings must be lubricated with a silicone grease to ensure easy, snug fit.
NOTE: Exhaust flue must slope 1.5° down towards the boiler 25 mm/m fall per metre of flue length.
Spacing ClipsSpacing Clips are available on request should they be required.NOTE: for eccentric vertical flue a 125 mm (5 in) diameter flashing plate will be required.
5.8.1 TWIN FLUE INSTRUCTIONS This part of the installation manual covers the installation and fi xing instructions of the twin fl ue eccentric fl ue duct systems only. When ordering twin fl ue it must be stated for WH 100/130 range. Typical installation procedures are illustrated by drawings.
Remove the front panel of the case(sect.8.1). Unscrew the screw (Fig.17 item 66) on the fl ue adapter.
Part. No Description SDO110050 Twin fl ue header F80/F80 PRO110200 Straight pipe L.1000 80 CUR110150 90° elbow bend 80 CUR110200 45° bend 80 GRI110050 Air inlet terminal 80 GRI110100 Exhaust terminal 80 TER060110 Vertical eccentric fl ue Terminal
Fig. 27
Fig. 26
27
Exhaust/suction system with concentric pipes for fl at or sloping roofs. Extensions with two separate pipes ( Fig. 25).
Maximum distance : T= L = 21+21 = 42 metre+Terminal Minimum distance : L = 0.5+0.5=1metre + Terminal Exhaust terminal must not be cut. NOTE: - If bends are used in the exhaust fl ue then horizontal - sections must be avoided and there must be a 1.5° slope - towards the boiler 25 mm fall per metre.
IMPORTANT: - See Fig. 5 for terminal clearances. - The pressure loss see table 3.
Exhaust/suction system with two separate rated 80 dia. Pipes - exhaust on fl at or sloping roof, suction from vertical wall ( Fig. 26).. Maximum distance D = L + L1 = 39.5 metre + Terminal Minimum total length = 2 metre NOTE: Exhaust fl ue must slope 1.5° down towards the boiler 25 mm fall per metre.
Exhaust/suction system with two separate pipes through a single vertical wall ( Fig. 27 ).
Maximum distance : D = L + L1 = 37 metre Minimum distance : D = L + L1 = 1 metre Min distance between pipe 50 mm.
IMPORTANT NOTICE: - inlet and exhaust terminals must never be installed on opposite walls of the building (PrEN 483).
- If the fl ue terminates less than 2 m above a balcony, above the ground, or above a fl at roof to which people have access, then a suitable terminal guard must be fi tted.- Fit only recommended fl ue terminal guard by securing concentrically around terminal with screws.
Available on request from: THE WHITE BOILER COMPANY Chartist Way,Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0044(0) 113 252 7007
5.8.2
5.8.3
5.8.4
IMPORTANT: Please, lubricate the internal part of the seals before being fitted.
5.9 INSTALLATION INSTRUCTIONS FOR CONCENTRIC 80/125 FLUE SYSTEM
L + L = 23.5m Max
Straight Flue Straight Flue 90° Offset Flue 135° Offset Flue L = 25 m Max L = 25 m Max L = 20 m Max L = 22.5 m Max plus Terminal plus Terminal plus Terminal plus Terminal
5.9.1 The vertical 80/125 flue kit is intended for use where a horizontal 60/100 flue outlet is not possible or desired. The vertical flue can be used either with a flat roof or a pitched roof (maximum pitch 60°). Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 135°/90° flue bend (Fig. 28).
Part No Description PR5094110A Straight fl ue header / sample point 60/100 PRO110300 Flue Extension 80/125 L1000 RID110050 125/80 to 100/60 Flue reducer CUR110250 45° fl ue bend 80/125 CUR110300 90° elbow fl ue bend 80/125 TER010050 Horizontal Flue Terminal 80/125 TER110200 Vertical Flue Terminal 80/125 TEG060050 Flashing sleeve/slate
IMPORTANT: - See Fig. 5 for terminal clearances. - The pressure loss see table 3 page 19.
Fig. 28 IMPORTANT NOTICE: - When using our vertical fl ue kit the 125 mm x 100 reducer is supplied complete with the vertical terminal simply remove this and fi x it into the fl ue adaptor on the top of the boiler.
Fig. 29
Available on request from: THE WHITE BOILER COMPANY Chartist Way,Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0044(0) 113 252 7007
NOTE : If using Flue arrangement in Fig. 28 then the 125x100 Flue reducer must be purchased separately.
28
IMPORTANT: Please, lubricate the internal part of the seals before being fitted.
Fig.31
5.10 ASSEMBLE BOILER
5.10.1 Fitting valve packRemove plastic caps from boiler connection and fit valves as per Fig. 31 using washers provided.
It is recommended fixing the valve pack before installing the boiler on the wall.
5.11 GAS CONNECTION (Fig. 31)
5.11.1 A minimum working gas pressure of 20 mbar (8 in w.g.) must be available at the boiler inlet at full flow rate (37 mbar for propane, 29 mbar for butane).
5.11.2 Fit gas service cock to the boiler via the union nut and connect gas pipe. Do not overtighten and use another spanner as a counter force to avoid straining internal connections.Important consult (sect 4.5.1).
5.12 CENTRAL HEATING CONNECTION (Fig. 31)
IMPORTANT: when initially filling the system (with the front cover off) open the manual air vent (fig. 30) tacking care to avoid spilling water, and re-close prior to commissioning and operating the boiler.
29
Fig.30
5.12.1 Before any central heating connections are made to the boiler all system valves should be opened and the system thoroughly flushed out with cold water.
- Connect the central heating return pipe to the isolating cock.
- Connect the central heating flow pipe to the isolating cock marked CHF.
- Pipe dimensions and positions are marked on template supplied and fig. 32.
5.13 DOMESTIC HOT WATER (Fig. 31)
5.13.1 The domestic hot water circuit does not need a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar. If in doubt it is advisable to install a pressure reducing valve. The minimum pressure needed to operate the domestic hot water system is 0.5 bar with a flow of approx 3 Lts per min. Flush out all foreign matter from the supply pipe before
and after connecting to the appliance. - Connect the 15 mm. cold water pipe to the
appliance inlet.- Connect the 15 mm. hot water pipe to the
appliance outlet.
30
5.14 SAFETY VALVE DISCHARGE
5.14.1 The safety valve is located to the rear (15 mm copper) to permit a discharge pipe to be connected. When connecting ensure the
discharge pipe does not restrict access. The discharge should terminate facing downward exterior to the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, in easily visible position, and not to cause damage to electrical components or wiring. The discharge must not be over an entrance or a window or any other type of access.
5.15 CONDENSATE DRAIN CONNECTION
5.15.1 The condensate drain connection is a flexible 3/4” pipe and is therefore adjustable Fig. 31.
The drain pipe should have a fall of a least 2.5° away from the boiler. Condensate should, if possible be discharged into the household internal drainage system.
If this is not practicable, discharge can be allowed into the external household drains or a purpose designed soak away.
It is recommended that any external condensate drain pipe is insulated and also must be of 40 mm (1” 1/2) diameter, through the outside wall to prevent freezing in adverse weather conditions.
The condensate is discharged periodically in “slugs” by siphonic action. It is not necessary to
provide air breaks or extra traps in discharge pipe as there is already a 125mm high trap inside the boiler.
Fitting an extra trap may cause the boiler siphon to work incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.
Notes: ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798
1 - INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP
2 - INTERNAL CONNECTION TO SOIL AN VENT STACK Make connection to SVP using a solvent welded saddle.
31
3 - TERMINATION TO SOAK AWAY 4 - TERMINATION TO DRAIN / GULLY
5.16 CONVERTING THE APPLIANCE TO DIFFERENT GAS TYPES
5.16.1 Boilers are factory set to work for use with Natural gas or LPG gas.This is
clearly marked on the packing and boiler data badge. To convert a boiler from one gas to another this operation must be carried out by a qualified competent person, with all necessary equipment autorised by the manufacturer.
It will also be necessary to obtain a data badge conversion kit directly from The White Boiler Company.
1 - Remove the case. 2 - Check gas mains pressure at the gas valve test nipple upstream (Fig.34) with boiler operating.Sect.6.8. 3 - Adjust Fan Speed as Sect.3 (technical data). 4 - Measure the level of CO2 as sect.6.9 and adjust to correct data settings information. 5 - Affix new data badge. 6 - Replace in reverse order.
5.17 ELECTRICAL CONNECTIONS
5.17.1 IMPORTANT: Electricity supply must be asspecified in clause (sect. 4.10).
- When controls external to the appliance are required, design of the external electrical circuits should be undertaken by a
competent person. In accordance with the IEE wiring regulations.
It is essential that all external controls are VOLT FREE. Factory fitted internal wiring must not be disturbed when wiring external controls.
- To gain access to the electrical box remove the front panel of the case as described in clauses sect. 8.1.4. You can slide towards the top the instrument panel box and push the retaining latches and remove the instrument panel (Sec. 8.19).- Heat resistant flexible cable is fitted between the isolator and the terminal block A 3 core cable of 0.75 mm2 (24x0,2 mm) to BS 6500.
Make sure all wires to the appliance are routed away from sharp edges and hot surfaces.
The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carrying conductors become taut before the earthing conductor. Securely tighten all terminal screws and arrange the cable with slack between the cord anchorage and the terminal block.
WARNING: If the supply cord is damaged, it must be replaced by a service engineer (supply cord available from The White Boiler Company).
5.18 PROGRAMMABLE TIMECLOCK
Instructions for use consult User’s Guide.
5.19 OUTDOOR SENSOR
For use, consult Outdoor Sensor instructions.
POSITION OF WATER AND GAS CONNECTIONS
32
Fig. 32
INSTRUMENT PANEL
Fig. 33
33
SECTION 6 COMMISSIONING
6.1 Each boiler has been through a rigorous operational procedure at our factory and should not require any further adjustment, if you are not the installer but just commissioning this boiler check that the boiler has been installed in accordance with
these instructions, and the integrity of the flue system and the flue seals, as described in the Flue installation section.
6.2 GAS SUPPLY INSTALLATION
6.2.1 Inspect the entire installation including the gas meter, test for soundness and purge, all as described in BS 6891.
In IE refer to IS 813:2002. 6.3 ELECTRICAL INSTALLATION Preliminary electrical systems checks to
ensure electrical safety shall be carried out by a competent person.
ALWAYS carry out the preliminary electrical system checks: i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter.
6.4 INITIAL FILLING OF THE SYSTEM Open central heating flow and return valves
Unscrew the cap on automatic air release valve positioned on the top of the pump housing one full turn (leave open permanently). - Close all air release taps on the central
heating system. - Gradually open stopcock at the filling point
connection to the central heating system until water is heard to flow.
- Starting with the lowest radiator open each air release tap in turn. Close it only when clear water, free of bubbles, flows out. In the same way release air from any high points in the pipework.
- Open the manual air vent at the boiler heat exchanger flow pipe, see fig. 30, may require repeating to assist commissioning.
- Continue filling the system until 1.5 bar register on gauge. Then turn off the filling points stopcock.
- Inspect the system for water soundness and remedy any leaks discovered.
6.5 SETTING THE HEATING SYSTEM DESIGN PRESSURE
The design pressure must be a min. 1 bar and max. 1.5 bar. These figures are read off the pressure gauge.- The actual reading should ideally be 1
bar + the height in metres to the highest point of the system above the base of theappliance (up to max of 1,5 bar).
N.B.: The safety valve is set to lift at 3 bar (30 mt/42.5 psi).- To lower the system pressure to the
required value remove at the drain point (fig. 35) or drain on the heating circuit.
6.6 FILLING THE HOT WATER SYSTEM Close all hot water draw-off taps. Open the cold water inlet cock. Slowly open each draw-off tap until clear
water is discharged.
6.7 LIGHTING THE BOILER Before lighting the boiler make sure that
the heating circuit flow and return valves are open and also that the cold water input cock is open.- If external controls are installed (e.g
timeclock and thermostat) make sure that they call for heat.
- Push Summer/Winter switch Fig.33 to Winter.
GAS VALVE
IMPORTANT: Before switching on the boiler POWER
SWITCH FOR THE FIRST TIME when commissioning, turn the heating control knob (Fig.33) DOWN TO ITS MINIMUM setting leaving it at minimum for approx 5 mins to purge air safely from the boiler heat exchanger.
Fig. 35
Fig. 34
- Turn control knob (Fig.33) down to its minimum setting.- Push the power main switch to on (Fig.33)- The digital display will show water set point temperature in central heating.- The fan starts and after a second or so the digital led display will show that the ignition has commenced.- NOTES : It maybe necessary to reset theDigital Timer on boiler (if fitted) to start.Put the timer to on position (Fig.33).-The ignition control will automatically have three attempts , but initially this may be due to air in the gas supply line.If the burner fails to light, the digital led display and fan will stop, and the display will show the lockout code.-If necessary push the boiler Reset button (Fig.33) and the boiler will restart automatically.- After the boiler has lit, allow to warm at minimum temperature setting to purge any air from the system.- Once the system has been purged of air turn the control knob to the desired position. With leak detection fluid test for gas tightness of all gas components and joints.See paragraph 6.14 for regulating the heating circuit control knob.
6.8 CHECK THE GAS PRESSURE Check the gas mains pressure at the gas
valve inlet pressure test (Fig.34) with boiler operating.
Check with the Local Gas supplier if the pressure differs significantly from 20 mbar G20 (natural gas), 37 mbar G31 (propane) and 29 mbar G30 (butane).
IMPORTANT : the Gas Valve Throttle adjuster is required to be sealed with tamper proof paint after adiustment
(fig. 34).
6.9 COMBUSTION CHECK Check gas carrying components along with,
the combustion of the appliance which should be checked as follows.
Remove the front panel of the case. Ensure the boiler and external controls are
calling for heat. Turn on electrical supply. Open the Hot water tap at maximum flow rate.
Wait at least five minutes or until the unit has reached its operating temperature.
Unscrew the test sample screw on the boiler elbow bend (Fig.10 item 60). Measure the level of CO2. Check the reading against the
corresponding value in sect.3 TECHNICAL DATA. If adjustment proves necessary
then proceed as follows.
IMPORTANT : Any adjustment to the gas valve should only be carried out by a qualified person.
Refer to tables 1/A, 1/B, 1/C and 1/D section 3 adjust the maximum level of CO2 by turning the Throttle (allen screw 2.5 mm) on the gas valve (Fig.34).
Anti-clockwise to increase CO2. Clockwise to decrease CO2 After any new regulation wait to stabilise
about one minute. - Replace the sample point screw on the flue manifold ( Fig.10 item 60). - Replace the front panel of the case.
IMPORTANT: do not insert analyser probe into the sample point immediately or for long periods. This will prevent saturation of the analyser.
During the calibration function the combustion ratio may increase for short time while the boiler performance is optimised.
The person carryng out a combustion measurement should have been asessed as competent in the use of a flue gas analyser and be able to interpret of the results. The flue gas analyser used should be one
meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturer’s requirements.
Fig. 36
ELECTRODES POSITION
34
Once the process of commissioning the boiler is complete, the commissioning engineer MUST complete his section in the Benchmarklog book.
ATTENTIONIT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK
COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE
6.10 CHECKING THE FLUE SYSTEM
6.10.1 The flue system should be visually checked for soundness. Check all connections and fixings are secure and tight.
6.11 CHECKING THE HEATING THERMOSTAT
6.11.1 Allow the system to warm up and then turn the C.H thermostat to ensure the main burner modulates from “high” to “low” and “low” to “off” and vice versa (scale range covers approx
45°C - 80°C).
6.12 TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW
6.12.1 CHECK THE OPERATIONAL (WORKING) INLET PRESSURE
Set up the boiler to operate at maximum rate by opening the hot tap to maximum flow. With the boiler operating at the maximum rate check the operational dynamic (working) gas pressure test complies with the requirements. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.
6.12.2 Put the appliance in summer position with the summer/winter switch (Fig.33). - Open a domestic hot water tap (preferably the bath tap). Ensure cold water inlet stopcock is open and the D.H.W. control knob (Fig.33) is set at maximum.
- Digital display shows water temperature in demand ( led on).
- If the boiler does not light check that the water flow rate is above the min. required to operate the differential pressure 2.8 Lts./min. (0.61 gals/min).
- The temperature of the water will depend on the rate at which it flows. If, due to high water pressure, the flow rate is too high (and the temperature too low for practical use) the flow rate may be adjusted. It is better to set for the lowest acceptable temperature preferably at the bath tap since the user can gain higher temperatures at other restricted flow taps.
- If the cold supply is subject to large fluctuations or is above the permitted max. water pressure, a suitable pressure/flow regulator should be fitted in the cold water supply to the appliance.
- Slowly close the draw off tap to reduce the flow rate to the min (approx. 2.8 litre/min).
- Rotate the D.H.W. control knob to ensure it operates at its various setting.
- Close the draw-off tap still further. The burner should stop when the rate falls below about 2.8 litres/min (0.61 gals/min).
35
Fig. 38
6.12.3 CHECKING MAX/MIN. FAN SPEED (see tables 5/A and 5/B).
6.12.4 To check max fan speed, place the jumper on JP16, and select the summer/ winter switch in winter position (DHW tap open). See sect. 6.14.1 and fig. 39. To check min fan speed, place the jumper on JP16, and select the summer/ winter switch in summer position (DHW tap open). See sect. 6.14.1 and fig. 39. This can be checked using a (frequency) meter JP2.
IMPORTANT: DO NOT ADJUST THE MINIMUM SET POTENTIOMETER R10, THIS IS SET AN SEALED. THIS CAN BE CHECKED USING A FREQUENCY METER JP2. (Fig. 39a).
- The operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder. This then ensures the greatest possible fuel economy consistent with household requirements of both heating and hot water consumptions.
Advise the User of the precautions necessary to prevent damage to the system, and to the building, in the event of the system remaining inoperative during frost conditions.
- Explain the function and the use of the boiler, the summer/winter switch, the ON/OFF switch and the reset of the digital display.- Explain and demonstrate the function
of temperature controls, neon lights, radiator valves etc for the economic use of the system.
- If an optional time clock is fitted, then draw attention to the time clock User’s Instructions and hand them to the Householder.
- Stress importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR.
- Fill in the Benchmark log book and leave completed with the customer.
6.13 KEEP HOT (Fig. 38).
The boiler comes with an optional keep hot facility. This can be switched on by placing the jumper JP14 on the circuit board over the pins, or remove this to cancel, then reset the boiler. This will result in the boiler, at any time, periodically firing to keep the water within the boiler up to temperature to reduce the time delay of hot water delivered to any hot draw off point.
6.14 RANGE RATING CENTRAL HEATING OR/AND DOMESTIC HOT WATER
The boiler comes set, in Central heating, at the MID RANGE of its output.
6.14.1 When the boiler operates in the C.H. mode, the fan speed, can be set between the min. and max. values. (See fig. 37). This permits capacity to be adjusted to suit system demand, if adjustment is required proceed as follows:
- Remove front casing (sect. 8.1.4). - Push the retaining latches and remove the front of the instrument panel (Fig. 54). - Place instrument front panel into service
holding bracket (just above control box (Fig. 55). - Place jumper on JP16 for test mode function, “Co” (Control) is dIsplayed on the digital display (see sect. 7.1). - Using a small screw driver to adjust the potentiometer R9 (CH max fan speed) or/and R19 (DHW max fan speed), clockwise to decrease the fan speed and anti-clockwise to increase the fan speed. - When viewing fan speed slightly move the potentiometer to display the speed and adjust only if necessary (fig. 37) the fan speed will flash the first two digits on the display in the control panel in rpm
(eg. 42 = 4200 rpm).
6.15 HANDING OVER TO THE USER
6.15.1 After completion of installation and commissioning of the system, the installer should hand over to the Householder by taking the following actions:
- Hand the “User’s Instructions” to the Householder and explain His/Her responsibilities under the “Gas Safety Regulations 2000”.- Explain and demonstrate the lighting and shutting down procedures.
Fig. 39a
37
SECTION 7 SERVICING INSTRUCTIONS
The White Boiler Company is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark was instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage in the regular servicing of all central heating systems to ensure safety and efficiency.
During routine servicing, and after any maintenance or change of part of the combustion circuit, the following must be checked:
- The integrity of the flue system and the flue seals.- The integrity of the boiler combustion circuit and the relevant seals.- The operational dynamic (working) gas inlet pressure at maximum rate.- The gas rate.- The combustion performance.
COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE.
Please note: BS6798:2009 Specification for installation and maintenance of gas-fired boilersof rated input not exceeding 70 kW net advises that:
- The person carryng out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results.- The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN 50379-3 and be calibrated in accordance with the analyser manufacturers requirements.- Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, Parts 1to 4.
7.1 SERVICE INFORMATION FUNCTION
When the jumper JP16 is inserted, “Co” (Control) is displayed on the digital display (fig. 33), no water or heating led are ON, only the yellow led is ON when boiler is running.In summer position, with DHW operating, it is possible to set the minimum power by R10 trimmer (Fig. 39).
In winter position, with heating operating, it is possible to set the maximun CH power by R9 trimmer. In DHW operation, it is possible to set the maximum DHW power by R19 trimmer.Moving the knob of a trimmer the fan speed is displayed flashing for 10 seconds on the digital display (see Technical data section 3, tables 5/A and 5/B page 34 and fig. 39).
7.2 SEQUENCE HISTORY CODES
It is possible to see up to the last ten sequence of events on the digital display by pushing the reset button for 10 seconds. In this case, when the function is enabled the 3 leds on the panel start flashing. Pushing the reset button again it is possible to view the others codes up to a maximum of ten.After the tenth, push the reset button to repeat the history.Exit from history is automatic after 10 seconds.The sequence history starts after 1 hour of first continuous power onto the board.
7.3 BOILER FROST PROTECTION
The appliance has built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature fallsbelow 10°C and will operate the burner when the temperature falls below 5°C.The burner will switch off when the temperature reaches 27°C.When the frost protection device operates “AF” is displayed on the digital display.
IMPORTANT NOTE:The system should be protected by incorporating a system frost thermostat.
Combustion testing must be carried out by competent person using a combustion analyser conforming to BS7927.
38
7.4 To ensure continued efficient operation of the appliance it is necessary to carry out servicing and cleaning at regular intervals.
The frequency of cleaning will depend upon the particular installation conditions and usage but in general, once a year is advisable.
WARNINGBefore the start of any servicing orreplacement of components alwaysisolate electricity supply to the applianceand always turn off the appliance gassupply at the gas service cock.
The Data badge is positioned low on left panel.
- The following notes apply to the appliance and its controls but it should be remembered that attention must also be paid to the heating and hot water circuits with special attention to radiator valves, thermostats, clocks, leaking hot water taps etc.
- Where it is necessary to replace a gasket that relies on adhesive for securing - this adhesive will be supplied with the gasket as a spare item.
- In all cases prior to servicing, remove the front panel of the case. Operate the appliance by turning the hot water services on to a high water flow, measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point.
- IMPORTANT: After completing any servicing or replacement of gas carrying components it is essential that a test for gas soundness is always carried out along with functional checks in operation.
7.5 TO INSPECT AND CLEAN THE APPLIANCE
7.5.1 Before carrying out cleaning operation, cover the electrical control panel with a piece of waterproof material to protect it from debris.
7.5.2 Inspect the heat exchanger for any blockage. Deposits of any material should be brushed away using a soft brush.
NOTE: Do not use brushes with metallic bristles.
7.5.3 Examine internal pipe-work connections and automatic air vent for any water leaks. Rectify if necessary.
7.5.4 Examine and remove loose debris from the combustion chamber using a soft brush and vacuum cleaner. Carefully flush, by spraying water any remaining debris through the condensate trap. (Ensure the water is kept away from electrical components).
7.5.5 Inspect the siphonic condensate trap for a blockage. Remove the cap at the base of the
condensate trap. Remove any solid found. Remove the float to clean it.
Any deposits should be flushed out. Reassemble and refit the condensing
trap. When refitting the cap ensure that a
watertight seal is achieved, but do not use excessive force.
7.5.6 Examine the spark and sensing electrodes for any mechanical damage, Clean away any debris and check the spark and sensing gap.
7.5.7 Examine flue duct and flue manifold and ensure that there is no obstruction. Examine the gasket at the entry into the flue manifold.
7.5.8 It is essential that a good seal is made at the outlet to the flue manifold, renew this gasket if there is any sign of damage or deterioration.
Fig.40
39
40
SECTION 8 REPLACEMENT OF PARTS
8.1 GENERAL
8.1.1 Replacement of parts must be carried out by a competent person. 8.1.2 Before replacing any parts the boiler should
be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler.
8.1.3 After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls.
8.1.4 For replacement of parts, the front,side and bottom panel panels of the boiler will need to be removed.
To remove the front panel unscrew the two cover screws that secure the front panel to the boiler and lift off.
To remove the bottom panel unscrew the four screws and lift off. To remove the side panels, remove the
front and bottom panels, unscrew the screw s below and remove (Fig.40) .
8.2 TO REMOVE/REPLACE SPARK IGNITER BOX (Fig. 41)
8.2.1 Remove the front casing (sect. 8.1.4).
8.2.2 Detach all the connectors from the igniter control box.
8.2.3 Remove the 2 screws that secure the spark igniter to the bracket.
8.2.4 Replace in reverse order.
Fig.42
8.3 TO REMOVE/ REPLACE THE ELECTRODES (Fig.36)
8.3.1 Remove the front casing panel (sect. 8.1.4).
8.3.2 Remove the ignition and/or sensing lead plug.
8.3.3 Unscrew the two securing screws and put them into a container so that they don’t get lost.
Withdraw the Spark electrode and /or sensing electrode carefully from the
combustion chamber cover being careful not to damage the seal.
8.3.4 Replace with new electrode in reverse order. Ensure gap is correct and there is a good seal when replaced.
8.4 TO REMOVE/REPLACE FAN (Fig. 42-43)
8.4.1 Remove front panel only (sect. 8.1.4).
8.4.2 Remove three manifold/burner retaining nuts Fig. 42).
Pull forward and lift up manifold slighty to remove.
Fig.41
41
Fig.44
8.5 TO REMOVE/REPLACE THE BURNER (FIG.45)
8.5.1 Remove front casing (sect. 8.1.4).
8.5.2 Follow instruction to remove fan (sect. 8.4 to 8.4.3).
8.5.3 Remove the burner from the main heat exchanger.
Important: the burner gasket may require replacing.
8.5.4 Replace in reverse order.
8.6 TO REMOVE/REPLACE THE HEAT EXCHANGER.
8.6.1 Remove front casing (sect 8.1.4) and the bottom, left and right side panels.
8.6.2 Drain the boiler CH circuit and drain the DHW circuit.
8.6.3 Follow instruction to remove fan (sect. 8.4 to 8.4.3).
8.6.4 Remove the clip securing the condense pipe out of the bottom of the heat exchanger and pull down to remove the pipe.
8.6.5 Disconnect the flow and return pipes at the heat exchanger.
8.6.6 Disconnect the pipes at the flow manifold and pump then move away from the heat exchanger.
8.6.7 Disconnect the pipes to the expansion vessel.
8.6.8 Remove the spark igniter box (sect. 8.2).
8.6.9 Loosen the four heat exchanger securing screws and clamps then carefully ease heat exchanger out.
CAUTION : There will be water in the heat exchanger.
8.6.10 Replace in reverse order, always use a new
“O”rings seals.
Fig.45
Fig.43
8.4.3 Detach power supply cables to fan (Fig.42). The fan and the manifold can then be remove from the boiler.
8.4.4 To separate the fan from manifold remove the two retaining bolts and the three screws retaining the air/gas mixture plate
(Fig. 43/44).
8.4.5 Reassemble in reverse order. Ensure wires are connected correctly.
8.7.4 Remove the electrical plug from the gas valve and unscrew the four screws to the gas inlet pipe.
8.7.5 Remove the gas valve.
8.7.6 Reassemble in reverse order and replace the gasket.
8.7.7 IMPORTANT : When gas control valve will be re -fitting, check combustion CO2 and adjusted if necessary see section 6.9.
8.7 TO REMOVE/REPLACE GAS VALVE . (Fig.46).
8.7.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the left side
panel.
8.7.2 Drop down the control panel into the service position (Fig. 55).
8.7.3 Unscrew and disconnect gas valve pipe (Fig. 46).
Fig.46
8.8 TO REMOVE/REPLACE EXPANSION VESSEL (Fig.47).
8.8.1 Remove front casing (sect 8.1.4) and the bottom panel.
Remove the bottom panel and the right side panel.
8.8.2 Drain the CH circuit.
8.8.3 Unscrew the fixing bracket. Unscrew the nut connecting the expansion vessel, and lift up the vessel and remove.
8.8.4 Replace in reverse order.
NOTE: Always use new gasket.
Fig.47
42
8.9 TO REMOVE/REPLACE PLATE HEAT EXCHANGER (Fig. 48-49).
8.9.1 Remove front casing (sect 8.1.4). Remove the bottom panel.
8.9.2 Follow instruction to drop down control box
sect. 8.20.
8.9.3 Close off on/off valves for CH circuit and DHW circuit and drain the boiler and drain hot water from the lowest hot water tap.
8.9.4 Unscrews the two allen screws that connect the DHW heat exchanger and pull it out from the boiler (Fig. 48).
8.9.5 If necessary the pipes from the flow manifold may have to be remove for easier access. Lift up the plate heat exchanger.
8.9.6 Replace in reverse order. NOTE: Always use new “O”rings.
8.10 TO REMOVE/REPLACE DIVERTER VALVE MOTOR (Fig. 50).
8.10.1 Remove front casing (sect 8.1.4).
8.10.2 Detach the electrical plug and remove the retaining clip.
8.10.3 Replace in reverse order.
8.11 TO REMOVE/REPLACE PUMP (Fig.51).
8.11.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the right side panel.
8.11.2 Drop down control box (sec. 8.20).
8.11.3 Detach the supply wire connector from the pump.
8.11.4 Remove the securing clip at the pump manifold (Fig. 51).
8.11.5 Remove the securing clip that fastens the pressure gauge to the pump. (Fig. 51).
8.11.6 Unscrew the nut that fastens the pump to the CH pipe and remove the pump.
8.11.7 Replace in reverse order.
NOTE : Alway use new seal and new “O” ring when re-fitting new pump.
43
Fig.48
Fig.49
Fig.50
8.12 TO REMOVE/REPLACE C.H. DIVERTER VALVE.
8.12.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the right side
panel.
8.12.2 Drop down control box (sec. 8.20).
8.12.3 Close the on/off valves for the heating circuit and drain the water at drain point Fig.35.
8.12.4 Remove diverter valve motor, to allow
access, (sect.8.10).
8.12.5 Unscrew the C.H.diverter valve as in Fig.52.
8.12.6 Replace in reverse order.
NOTE: Always use new “O” ring.
8.13. TO REMOVE/REPLACE DHW DIVERTER VALVE MECHANISM ( Fig. 52).
8.13.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the right side
panel.
8.13.2 Drop down control box (sec. 8.20).
8.13.3 Close the on/off valve for the DHW circuit and drain the hot water from the lowest hot water tap.
8.13.4 Remove the flow detector as fig.52. 8.13.5 Unscrew the DHW diverter valve as in
fig.52.
8.13.6 Replace in reverse order.
NOTE: Always use new “O”ring.
8.14 TO REMOVE/REPLACE AUTOMATIC AIR VENT (Fig. 51).
8.14.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the right side panel.
8.14.2 Close the on/off valves for C.H. circuit and drain the water from at drain point Fig.35.
8.14.3 Remove the pump see sect.8.11.
8.14.4 Remove the retaining clip holding the automatic air vent.
8.14.5 Pull the automatic air vent from the pump.
8.14.6 Replace in reverse order and check for leak.
NOTE: Fit a new “O” ring.
8.15 TO REMOVE/REPLACE THE CENTRAL HEATING AND/OR DOMESTIC HOT WATER THERMISTOR (Fig. items 27/8).
8.15.1 Remove front casing (sect 8.1.4).
8.15.2 Remove the wires that connect the thermistors.
8.15.3 For C.H. thermistor remove the retaining clip from the pipe.
8.15.4 For D.H.W. thermistor close the on/off valve
for the DHW circuit and drain the hot water from the lowest hot water tap.
Unscrew the thermistor.
NOTE: When reconneting the polarity of the wiring to thermistor is unimportant.
8.15.5 Replace in reverse order and replace the D.H.W. thermistor gasket.
44
Fig.51
Fig.52
8.16 TO REMOVE/REPLACE OVERHEAT THERMOSTAT (Fig. 1 item 25).
8.16.1 Remove front casing (sect 8.1.4). 8.16.2 Remove the two wires that connect to the
overheat thermostat.
8.16.3 Unscrew the thermostat to the heat exchanger and remove.
8.16.4 Replace in reverse order.
8.17 TO REMOVE/REPLACE LOW WATER OR DIFFERENTIAL PRESSURE SWITCH
(Fig. 53).
8.17.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the right side panel.
8.17.2 Close the on/off valves for central Heating circuit and drain the water from the boiler (Fig. 35).
8.17.3 Pull wires off and unscrew the low water pressure switch from pump manifold.
8.17.4 Remove the retaining clip that fix the electrical connection and unscrew the nut at the flow water pressure switch.
8.17.5 Replace in reverse order, fill the system as described in sect.6.4 and check for leaks.
8.18 TO REMOVE/REPLACE SAFETY DISCHARGE VALVE.
8.18.1 Remove front casing (sect 8.1).
8.18.2 Drop down control box (sec. 8.20).
8.18.3 Close the on/off valves for central Heating circuit and drain the water from the boiler
(Fig. 35).
8.18.4 Unscrew the screw below the valve.
8.18.5 Remove the securing clip and remove the pipe. Detach the valve.
8.18.6 Replace in reverse order, fill the system as described in sect.6.4 and check for leaks.
8.19 TO REMOVE INSTRUMENT PANEL. 8.19.1 Remove front casing (see sect. 8.1.4).
Fig.53
45
8.19.2 Push the four retaining latches and remove the front of the instrument panel (Fig. 55). 8.19.3 Rotate the instrument panel and put it in the service retaining clip instrument panel box bracket (Fig. 56).
8.20 TO REMOVE CONTROL PANEL BOX (Fig. 57). 8.20.1 Remove front casing (see sect. 8.1.4).
8.20.2 To move the control panel box into service position. 8.20.3 Draw forward the control panel box with both hands until it is slighty out of the boiler. As doing so move the box over to the left while still pulling it forward until the control box becomes free.
8.20.4 This will allow free access to lower part of the boiler.
46
Fig.54
8.21 TO REMOVE/REPLACE CONTROL BOARD (Fig.59).
8.21.1 Remove front casing (sect 8.1.4). Remove instrument panel (sect. 8.19.2 to
8.19.3).
8.21.2 Detach the connectors from the board.
8.21.3 Detach the PCB board from its base by unscrewing the four securing screws. (Fig. 59).
8.21.4 Replace in reverse order.
NOTE: When refitting the control panel ensure the leads are not trapped.
8.22 TO REMOVE/REPLACE TIMECLOCK.
8.22.1 Remove front casing (sect 8.1.4). Remove instrument panel (sect. 8.19.2 to
8.19.3).
8.22.2 Pull the two securing clip that fasten the timeclock to the panel instrument, and pull it out.
8.22.3 Carefully remove the four wire connecting timer.
8.22.4 Replace in reverse order.
NOTE: Ensure all electrical connections are made correctly.
Fig.55
Fig.56
8.23 TO REMOVE/REPLACE DIGITAL DISPLAY BOARD.
8.23.1 Remove front casing (sect 8.1.4). Remove instrument panel (sect. 8.19.2 to
8.19.3).
8.23.2 Detach the connectors from control board. Detach the connectors from the board.
8.23.3 Detach the Digital Display board from panel instruments by unscrewing the
four securing screws.
8.23.4 Replace in reverse order
47
8.24 TO REMOVE/REPLACE THE MAIN SWITCH (Fig. 33). 8.24.1 Remove front casing (sect 8.1.4) and push the retaining latches and remove the instrument panel.
8.24.2 Pull off the switch knob. Remove the switch out from the instrument panel by pressing the clamp springs.
8.24.3 Detach the wires that connect to the switch, make sure that these wires are later reconnected to the same poles.
8.24.4 Replace in reverse order.
Fig.57
Fig.59
8.25 TO CLEAN AND REMOVE/REPLACE CONDENSING TRAP (Fig.60).
8.25.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the left side panel.
8.25.2 Drop down control box (sec. 8.20).
8.25.3 Remove the securing clip and pull out the plastic pipe that connect the condensing trap at the heat exchanger.
8.25.4 Unscrew the nut that fasten the condensing trap to the depression chamber and remove it.
8.25.5 Replace in reverse order.
Fig.58
48
8.27 TO REMOVE/REPLACE FLUE TEMPERATURE SENSOR (Fig. 61).
8.27.1 Remove front casing (sect 8.1.4).
8.27.2 Detach the electrical plug and unscrew the sensor.
8.27.3 Replace in reverse order.
Fig.60
Fig. 62
Fig. 61
8.28 EXTERNAL CONTROL CONNECTION (Fig. 62).
8.28.1 Remove front and bottom of the casing (sect 8.1.4).
8.28.2 Remove the external wire link on the PCB box. 8.28.3 Replace with external wire controls.
8.29 FAN FREQUENCY CONTROL (Fig. 62).
8.29.1 Remove front casing (sect 8.1.4).
8.29.2 Connect the instrument to the PCB box fig. 62.
8.26 TO REMOVE/REPLACE THE WATER
PRESSURE GAUGE (Fig. 51).
8.26.1 Remove front casing (sect 8.1.4). Remove the bottom panel and the right side panel.8.26.2 Drop down control box (sec. 8.20).
8.26.3 Close the on/off valves for the heating circuit and drain the water at the drain point Fig.35. Remove the retaining clip on gauge pipe Fig. 51.
8.26.4 Remove the pressure gauge from the instrument panel by pressing its fastening springs.
8.26.5 Replace in reverse order.
49
SECTION 9 FAULT FINDING CENTRAL HEATING Before trying to operate the boiler make sure that: - All gas supply cocks are open and the gas supply has been purged of air. - The heating system pressure is at least 1 bar min to 1.5 bar Max. - Main Switch on. - Select “Winter”. - Central Heating control knob to maximum. - Ensure external controls calling for heat (Room stat/Timeclock/TRV).
Does heating LCD on digital display illuminate?
No
Is 230 at L-N connections on control board?
No
Check/Replace external Fuse and supply
Yes Replace On/Off Switch
Does the pump run?
Is low pressure in the system?
Re-pressure the system
Is 230V at pump
Check/Replace pump if necessary No Yes
Yes
No
Yes
Is there continuity at summer/winter switch?
Replace summer/winter switch
Check /Replace Timeclock if OK Replace control board
No
Yes
No
Is the burner led illuminate on control panel?
Yes
No Is 17 displayed Yes
FAN SEQUENCE CODE - Check Fan Voltage - Check fan
No
Is 01 displayed Yes
IGNITION SEQUENCE CODE - Check condensate drain if is not blocked - Check gas valve operation - Check the fan starts - Check Ignition control board and cables - Overheat thermostat not connected
Is 28 displayed
Is 12 displayed
LOW WATER /DIFFERENTIAL PRESSURE SWITCH OR PUMP SEQUENCE CODE - Check /Replace Low water pressure switch - Check pump - Check system pressure
OVERHEAT SEQUENCE CODE - Check the overheat thermostat
Yes
No
RESET THE BOILER - Push the Reset button on Digital Display and check LCD if illuminate
Yes
Does boiler go off before set point? Yes
- Check if the system has been purge of air - Check / Replace Automatic air vent
No - Check Domestic Hot Water
NOTE : See Section 10 page 51 for LED DISPLAY CODE
Is 30 displayed
FLUE TEMPERATURE SEQUENCE CODE - Check operating system
Yes
No
Is 31 displayed
No FLUE TEMPERATURE SEQUENCE CODE - Check / Replace fl ue sensor Yes
50
FAULT FINDING DOMESTIC HOT WATER Before continuing it may be necessary to see Central Heating Fault Finding (Sect.9): - All gas supply cocks are open and the gas supply has been purged of air. - The heating system pressure is at least 1 bar min to 1.5 bar Max. - Main Switch on. - Select “Summer” (Fig.50 item 1A). - Domestic Hot Water control knob to maximum. - Open Domestic hot tap close to the appliance.
Ensure Domestic Hot Water fl ow is min. of 3 l/min
Check fi lters are clean No
Is low pressure in the system?
Re-pressure the system
Check Microswitch on shunt valve being operate mechanically
Check/Replace diverter valve No Yes
Yes
No
Yes
No
Does the burner led illuminate on control panel?
Yes
No Yes DHW SENSOR SEQUENCE CODE - Check /Replace DHW sensor and cables
No
Yes
Is 28 displayed
Is 12 displayed
LOW WATER PRESSURE SWITCH SEQUENCE CODE - Check /Replace Low water pressure switch - Check system pressure
Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the manu acturers instructions and the data elds on the commissioning chec listcompleted in full.
o instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation.
o maintain the boiler guarantee it is essential that the boiler is ser iced annually by a as afe registered engineer who has been trained on the boiler installed.
he ser ice details should be recorded on the enchmar er ice Inter alecord and left with the householder.
60
ll installations in ngland and ales must be noti ed to ocal uthority uilding Control ( C) either directly or through a Competent ersons cheme. uilding egulations Compliance Certi cate will then be issued to the customer.
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstratingcompliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
ailure to install and commission according to the manufacturer s instructions and complete this enchmar Commissioning Chec list will in alidate the warranty. his does not affect the customer s statutory rights.
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
Customer name elephone number
ddress
oiler ma e and model
oiler serial number
Commissioned by ( I ) as afe register number
Company name elephone number
Company address
Commissioning date
To be completed by the customer on receipt of a Building Regulations Compliance Certi cate
ime and temperature control to heatingoom thermostat and programmer timer rogrammable room thermostat
oad weather compensation Optimum start control
ime and temperature control to hot water Cylinder thermostat and programmer timer Combination oiler
Heating one al es Fitted ot required
Hot water one al es Fitted ot required
hermostatic radiator al es Fitted ot required
utomatic bypass to system Fitted ot required
oiler interloc ro ided
ALL SYSTEMS
he system has been ushed and cleaned in accordance with and boiler manufacturer s instructions Yes
hat system cleaner was used
hat inhibitor was used uantity litres
Has a primary water system lter been installed Yes o
CENTRAL HEATING MODE measure and record
as rate m hr OR ft hr
urner operating pressure (if applicable) mbar OR as inlet pressure mbar
Central heating ow temperature C
Central heating return temperature C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (abo e ppm) Yes o
If yes and if required by the manufacturer has a water scale reducer been tted Yes o
hat type of scale reducer has been tted
DOMESTIC HOT WATER MODE easure and ecord
as rate m hr OR ft hr
urner operating pressure (at ma imum rate) mbar OR as inlet pressure at ma imum rate mbar
Cold water inlet temperature C
Hot water has been chec ed at all outlets Yes Temperature C
ater ow rate I min
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer s instructions and or Yes
ALL INSTALLATIONS
ecord the followingt ma . rate CO ppm AND CO CO² Ratio
t min. rate (where possible) CO ppm AND CO CO² Ratio
The heating and hot water system complies with the appropriate uilding Regulations Yes
The boiler and associated products ha e been installed and commissioned in accordance with the manufacturer s instructions Yes
The operation of the boiler and system controls ha e been demonstrated to and understood by the customer Yes
The manufacturer s literature including enchmar Chec list and er ice Record has been e plained and left with the customer Yes
Commissioning ngineer s ignature
Customer s ignature
(To con rm satisfactory demonstration and receipt of manufacturer s literature)
www.centralheating.co.u
THE WHITE BOILER COMPANY
61
ll installations in ngland and ales must be noti ed to ocal uthority uilding Control ( C) either directly or through a Competent ersons cheme. uilding Regulations Compliance Certi cate will then be issued to the customer.
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
efore completing the appropriate er ice Record below please ensure you ha e carried out the ser ice as described in the manufacturer s instructions. lways use the manufacturer s speci ed spare part when replacing controls.
SERVICE RECORD
SERVICE 01 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 02 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 03 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 04 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 05 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 06 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 07 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 08 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 09 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
Comments
ignature
SERVICE 10 ate
ngineer nameCompany nameTelephone o
as safe register o
Recordt ma . rate CO ppm AND CO² %t min. rate ( here ossible) CO ppm AND CO² %
